Lightweight shoes

ABSTRACT

According to an embodiment of the present disclosure, a lightweight shoe comprises an outsole and a vamp attached or sewn to the outsole to cover a foot, wherein the vamp includes a foam member and a fiber layer to surround the foam member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2015-0095831, filed on Jul. 6, 2015, in the Korean intellectual Property Office, the disclosure of which is incorporated by reference herein in its entirety.

Technical Field

Embodiments of the present disclosure concern lightweight shoes, and more specifically, to lightweight shoes including a foam member (e.g., a Styrofoam member) with a relatively lower specific gravity.

Discussion of Related Art

A shoe may include a vamp to cover and protect the foot and soles, including, e.g., an insole, midsole, or insole. The vamp may be formed of leather or fabric. The soles may be formed of rubber, polyurethane (PU) foam, ethylene vinyl acetate (EVA) foam, or other synthetic resins to provide durability. However, conventional shoes formed of such materials are heavy. To lighten up the shoes, the materials used for the shoes end up thickening. Thus, a need exists for shoes formed of lightweight materials.

SUMMARY

According to an embodiment of the present disclosure, a lightweight shoe comprises an outsole and a vamp attached or sewn to the outsole to cover a foot. The vamp may include a foam member and a fiber layer to surround the foam member.

The foam member may include at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS).

The fiber layer may include at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.

The lightweight shoe may further comprise a midsole formed on the outsole, wherein the midsole includes a foam member and a fiber layer to surround the foam member.

The foam member may include at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS).

The fiber layer may include at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.

The midsole may include an open-top protection layer with a U-shaped cross section and a foam member filling the protection layer or the midsole includes a protection layer with an opened top and bottom and a foam member fitted in the protection layer.

The protection layer may include at least one of polyurethane or ethylene vinyl acetate.

The protection layer may be a fiber layer including at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.

The foam member may include at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS).

According to an embodiment of the present disclosure, a lightweight shoe comprises an outsole and a vamp attached or sewn to the outsole to cover a foot. The outsole may include an open-top protection layer having a substantially U-shaped cross section and a foam member filling the protection layer.

The protection layer may include at least one of polyurethane, ethylene vinyl acetate, or rubber.

The protection layer may be a fiber layer including at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.

The foam member may include at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS).

According to an embodiment of the present disclosure, a lightweight shoe comprises an outsole, a vamp attached or sewn to the outsole to cover a foot, and an insole provided between the outsole and the vamp. The insole may include a foam member and a fiber layer formed on the foam member.

The fiber layer may include at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.

The foam member may include at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS).

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the present disclosure and many of the attendant aspects thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a cross-sectional view illustrating a material used in a lightweight shoe according to an embodiment of the present disclosure;

FIG. 2 is a side view illustrating a lightweight shoe according to an embodiment of the present disclosure, wherein a magnified cross section of a vamp of the lightweight shoe is shown;

FIG. 3 is a side view illustrating a lightweight shoe according to an embodiment of the present disclosure, wherein a magnified cross section of a midsole of the lightweight shoe is shown;

FIG. 4 is an exploded perspective view illustrating a lightweight shoe according to an embodiment of the present disclosure;

FIG. 5 is a cross-sectional view illustrating a lightweight shoe according to an embodiment of the present disclosure;

FIG. 6 is an exploded perspective view illustrating a lightweight shoe according to an embodiment of the present disclosure;

FIG. 7 is a cross-sectional view illustrating a lightweight shoe according to an embodiment of the present disclosure;

FIG. 8 is an exploded perspective view illustrating a lightweight shoe according to an embodiment of the present disclosure; and

FIG. 9 is a cross-sectional view illustrating a lightweight shoe according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

Hereinafter, exemplary embodiments of the inventive concept will be described in detail with reference to the accompanying drawings. The inventive concept, however, may be modified in various different ways, and should not be construed as limited to the embodiments set forth herein. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “adjacent to” another element or layer, it can be directly on, connected, coupled, or adjacent to the other element or layer, or intervening elements or layers may be present.

Hereinafter, embodiments of the present disclosure are described in detail with reference to the accompanying drawings. Like reference denotations may be used to refer to the same or similar elements throughout the specification and the drawings.

Typically, the vamp, outsole, or midsole of a shoe may be formed of various materials and have a predetermined weight to maintain their basic shape and durability against friction. For example, the vamp, which is a portion of the shoe to surround the foot, may be generally formed by joining woven or knitted fabric pieces formed of various types of fiber to allow the shoe a predetermined level of durability while maintaining the shape of the shoe. The outsole and midsole, which are portions of the shoe exposed to the outside, may be formed of rubber, polyurethane (PU) foam or ethylene vinyl acetate (EVA) foam with a good anti-wear property. Such materials have a higher weight and poses a limit on lightening up the shoe. To make the shoe lighter, a cushioning sponge layer with a specific gravity of 0.12 or less and a lower hardness may be disposed. In such case, however, the outer wall of the sponge layer may be exposed, resulting in an increased compression deformation and reduced cushioning. Therefore, the shoe may be less comfortable. According to an embodiment of the present disclosure, a fiber layer or plastic layer may be formed on an outer surface of a foam member (e.g., a Styrofoam member) with a specific gravity of about 0.01 to about 0.09.

When the shoe is formed of polyurethane foam or ethylene vinyl acetate foam with a specific gravity of 0.1 or less to reduce the weight of the shoe, the restoration of the shoe may be significantly reduced, thus rendering it difficult to maintain its shape and cushioning. According to an embodiment of the present disclosure, the foam member (e.g., a Styrofoam member) with a specific gravity of 0.01 to 0.09 may be used to form the shoe, and thus, the shoe may be lightened up while maintaining its restorative force.

FIG. 1 is a cross-sectional view illustrating a material used in a lightweight shoe according to an embodiment of the present disclosure. Referring to FIG. 1, a foam member (e.g., a Styrofoam member) 10 may be used as a basic material, and a fiber layer 20 may surround the foam member 10. The fiber 20 may prevent scratches or damage to the foam member 10.

FIG. 2 is a side view illustrating a lightweight shoe according to an embodiment of the present disclosure, wherein a magnified cross section of a vamp of the lightweight shoe is shown. Referring to FIG. 2, a material including, e.g., a foam member 10 and a fiber layer 20, to may be used to form a vamp 110 of the lightweight shoe, according to an embodiment of the present disclosure. According to an embodiment of the present disclosure, the lightweight shoe may include a vamp 110, a midsole 120, and an outsole 130. The vamp 110 may be attached to the midsole 120 by, e.g., an adhesive, or may be sewn to the midsole 120. The vamp 110 may be attached or fastened to the midsole 120 or a portion between the midsole 120 and the outsole 130, or an edge of the outsole 130. Although the lightweight shoe includes the midsole 120 and the outsole 130 in the instant embodiment, this is merely an example, and alternatively, the lightweight shoe may include the outsole 130 without the midsole 120.

The vamp 110 may include a foam member 111 (e.g., a Styrofoam member) and a fiber layer 112 surrounding the foam member 111. The vamp 110 may have various shapes. According to an embodiment of the present disclosure, each component of the lightweight shoe may be formed in a unit, and such units may be combined or joined to form the lightweight shoe. For example, the vamp 110 may be formed by combining or joining multiple material units. The whole foam member may be formed of a single piece of Styrofoam, and the fiber layer may be formed to surround the foam member. When the vamp 110 is formed by combining multiple material units, the vamp 110 may secure flexibility without performing a separate forming process.

The foam member 110 may be formed of at least one of expanded polypropylene (EPP), expanded polystyrene (EPS), or expanded polyethylene (EPE). The specific gravity of the foam member 111 may be about 0.01 to about 0.09. When the specific gravity of the foam member 111 is more than 0.09, the shoe may be less lightened up, and when the specific gravity of the foam member 111 is less than 0.01, the foam member may have a reduced restorative force, rendering it difficult to maintain the shape or cushioning of the shoe.

Expanded polystyrene (EPS), a sort of polystyrene, shows an excellent shock-absorption to effect and may be used for a thermal insulator thanks to its low thermal conductivity. Expanded polystyrene (EPS) has a lower density and is recyclable.

The fiber layer 112 may include reinforced fiber, e.g., at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber or ultra-high molecular weight resin fiber. The fiber layer 112 may be formed of, e.g., woven or knitted fabric or unwoven fabric, but not limited thereto.

For example, when the fiber layer 112 is formed of unwoven fabric, the fiber layer 112 may have a reduced apparent density along with increased air permeability. When the fiber layer 112 is formed of unwoven fabric, the fiber layer 112 may have a porous structure with a reduced apparent density, thereby leaving the overall weight of the shoe being reduced.

When the fiber layer 112 is formed of aramid fiber, the fiber layer 112 may have an increased heat resistance along with an increased tensile strength and elasticity, thereby leading to increased durability. For example, the fiber layer 112 may be formed of aramid woven fabric with excellent rub resistance and easy to manufacture, but not limited thereto. Upon fabricating woven fabric, aramid fiber may be used as the warp to form a warp beam, and the warp beam may be mounted on a loom. Aramid fiber may then be used as the weft, thereby forming woven fabric. The aramid fabric may have a plain weave or basket weave. The plain weave or basket weave, because the warp and weft formed to have a predetermined curvature, may evenly distribute an external force to the overall fabric, thereby leading to increased rub resistance.

Examples of the ultra-high molecular weight resin fiber may include ultra-high molecular polyethylene, ultra-high molecular polypropylene, or ultra-high molecular polyester. Such ultra-high molecular weight resin fiber may be a substance with an average molecular mass of about 1 million or more, may have a structure of a linear molecular sieve, and may exhibit a good anti-wear property or strength. According to an embodiment of the present disclosure, when the vamp 110 includes the fiber layer 112, the anti-impact property may be increased.

FIG. 3 is a side view illustrating a lightweight shoe according to an embodiment of the present disclosure, wherein a magnified cross section of a midsole of the lightweight shoe is shown. Referring to FIG. 3, a material including, e.g., a foam member 121 and a fiber layer 122, may be used to form a midsole 120 of the lightweight shoe, according to an embodiment of the present disclosure. According to the instant embodiment, the lightweight shoe may include a vamp 110, the midsole 120, and an outsole 130.

The midsole 120 may include as foam member 121 (e.g., a Styrofoam member) and a fiber layer 122 surrounding the foam member 121. The foam member 121 and the fiber layer 122 used in the midsole 120 may include substantially the same materials as those used in the embodiment described above in connection with FIG. 2.

For example, when the midsole or outsole is formed of the foam member 121, e.g., a Styrofoam member, a protection layer may be formed on the foam member 121 to prevent damage to the foam member 121 due to rubbing against the ground.

FIG. 4 is an exploded perspective view illustrating a lightweight shoe according to an embodiment of the present disclosure. FIG. 5 is a cross-sectional view illustrating a lightweight shoe according to an embodiment of the present disclosure. Referring to FIGS. 4 and 5, the lightweight shoe includes a vamp 110, a midsole 120, and an outsole 130. The vamp 110 may be attached to the midsole 120 by, e.g., an adhesive, or may be sewn to the midsole 120, The vamp 110 may be attached or fastened to the midsole 120 or a portion between the midsole 120 and the outsole 130, or an edge of the outsole 140.

The midsole 120 may include an open-top protection layer 124 with a U-shaped cross section and a foam member 123 filling the protection layer 124.

Alternatively, the midsole 120 may include a protection layer 124 whose top and bottom are opened and a foam member 123 put in the protection layer 124.

According to an embodiment of the present disclosure, the foam member 123 may be formed of substantially the same materials or structure as that described above in connection with FIG. 2.

When the protection layer 124 is formed to have a U-shaped cross section or to have an opened top and bottom, the midsole 120 may be formed by preparing the protection layer 124 as a mold and forming the foam member 123 inside the protection layer 124 or by forming the foam member 123 in substantially the same shape as the protection layer 124 and fitting the foam member 123 in the protection layer 124. By the above method, the midsole 120 may be manufactured in a simplified process.

The protection layer 124 may be formed of various materials. The midsole 120 may include at least one of polyurethane or ethylene vinyl acetate to provide sufficient elasticity. The midsole 120 may include a fiber layer formed of at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber to provide lightness.

In the instant embodiment, the fiber layer as the protection layer 124 may include substantially the same substance as that of the fiber layer described above in connection with FIG. 2.

FIG. 6 is an exploded perspective view illustrating a lightweight shoe according to an embodiment of the present disclosure. FIG. 7 is a cross-sectional view illustrating a lightweight shoe according to an embodiment of the present disclosure.

Referring to FIGS. 6 and 7, an outsole 130 may include substantially the same materials as those used in the midsole described above in connection with FIGS. 4 and 5. According to the instant embodiment, the lightweight shoe may include a vamp 110, a midsole 120, and the outsole 130. Although the lightweight shoe includes the midsole 120 and the outsole 130 in the instant embodiment, this is merely an example, and alternatively, the lightweight shoe may include the outsole 130 without the midsole 120.

According to an embodiment of the present disclosure, the midsole 130 may include an open-top protection layer 134 with a U-shaped cross section and as foam member 133 filling the protection layer 124.

According to an embodiment of the present disclosure, the foam member 123 may be formed of substantially the same materials or structure as that described above in connection with FIG. 2. The protection layer 124 may be formed of various materials. The outsole 130 may include at least one of polyurethane, ethylene vinyl acetate, or rubber to provide sufficient elasticity and predetermined hardness. The outsole 130 may include a fiber layer formed of at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber to provide lightness.

In the instant embodiment, the fiber layer as the protection layer 124 may include substantially the same substance as that of the fiber layer described above in connection with FIG. 2.

FIG. 8 is an exploded perspective view illustrating a lightweight shoe according to an embodiment of the present disclosure. FIG. 9 is a cross-sectional view illustrating a lightweight shoe according to an embodiment of the present disclosure. Referring to FIGS. 8 and 9, an insole 140 may include substantially the same materials as those used in the midsole described above in connection with FIGS. 4 and 5. According to an embodiment of the present disclosure, the lightweight shoe may include a vamp 110, a midsole 120, an outsole 130, and an insole 140. The to vamp 110 may be attached to the midsole 120 by, e.g., an adhesive, or may be sewn to the midsole 120. The vamp 110 may be attached or fastened to the midsole 120 or a portion between the midsole 120 and the outsole 130, or an edge of the outsole 130. The insole 140 may be a portion of the lightweight shoe which contacts the foot. The insole 140 may be fastened inside the lightweight shoe. The insole 140 may be detachably provided. Although the lightweight shoe includes the midsole 120 and the outsole 130 in the instant embodiment, this is merely an example, and alternatively, the lightweight shoe may include the outsole 130 without the midsole 120.

The insole 140 may include a foam member 141 (e.g., a Styrofoam member) and a fiber layer 142 formed on the foam member 141 to maintain the shape or cushioning of the lightweight shoe.

The fiber layer 142 of the insole 140 may be formed of substantially the same material as the fiber layer 112 described above in connection with FIG. 2.

The foam member 140 may form a body of the insole 140. The foam member 140 may be formed of substantially the same material as that used in the embodiment described above in connection with FIG. 2.

As such, since the foam member 140 (e.g., a Styrofoam member) may be used to form the vamp 110, the midsole 120, the outsole 130, or the insole 140, the lightweight shoe may be made lighter along with increased durability and cushioning as compared with conventional shoes.

According to embodiments of the present disclosure, the shoes may be formed of a foam member (e.g., a Styrofoam member) to provide lightness and a protection layer formed on the foam member to protect the foam member, thus rendering the weight of the shoes to be reduced. The foam member may be porous to thereby provide enhanced thermal insulation.

While the inventive concept has been shown and described with reference to exemplary embodiments thereof, it will be apparent to those of ordinary skill in the art that various changes in form and detail may be made thereto without departing from the spirit and scope of the inventive concept as defined by the following claims. 

What is claimed is:
 1. A lightweight shoe, comprising: an outsole; and a vamp attached or sewn to the outsole to cover a foot, wherein the vamp includes a foam member and a fiber layer to surround the foam member.
 2. The lightweight shoe of claim 1, wherein the foam member includes at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded in polystyrene (EPS).
 3. The lightweight shoe of claim 1, wherein the fiber layer includes at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultrahigh molecular weight resin fiber.
 4. A lightweight shoe, comprising: an outsole; a midsole formed on the outsole; and a vamp attached or sewn to the midsole to cover a foot, wherein the midsole includes a foam member and a fiber layer to surround the foam member.
 5. The lightweight shoe of claim 4, wherein the foam member includes at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS).
 6. The lightweight shoe of claim 4, wherein the fiber layer includes at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.
 7. The lightweight shoe of claim 4, wherein the midsole includes an open-top protection layer with a U-shaped cross section and a foam member filling the protection layer or the midsole includes a protection layer with an opened top and bottom and a foam member fitted in the protection layer.
 8. The lightweight shoe of claim 7, wherein the protection layer includes at least one of polyurethane or ethylene vinyl acetate.
 9. The lightweight shoe of claim 7, wherein the protection layer is a fiber layer including at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.
 10. The lightweight shoe of claim 7, wherein the foam member includes at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS).
 11. A lightweight shoe, comprising: an outsole; and a vamp attached or sewn to the outsole to cover a foot, wherein the outsole includes an open-top protection layer laving a substantially U-shaped cross section and a foam member filling the protection layer.
 12. The lightweight shoe of claim 11, wherein the protection layer includes at least one of polyurethane, ethylene vinyl acetate, or rubber.
 13. The lightweight shoe of claim 11, wherein the protection layer is a fiber layer including at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.
 14. The lightweight shoe of claim 11, wherein the foam member includes at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS).
 15. A lightweight shoe, comprising: an outsole: a vamp attached or sewn to the outsole to cover a foot; and an insole provided between the outsole and the vamp, wherein the insole includes a foam member and a fiber layer formed on the foam member.
 16. The lightweight shoe of claim 15, wherein the fiber layer includes at least one of chemical fiber, glass fiber, carbon fiber, aramid fiber, or ultra-high molecular weight resin fiber.
 17. The lightweight shoe of claim 15, wherein the foam member includes at least one of Styrofoam™, expanded polyethylene (EPE), expanded polypropylene (EPP), or expanded polystyrene (EPS). 